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’04-‘05 KTM 450/525 EXC & MXC
DUAL SPORT KIT INSTALLATION MANUAL
1. Get a degree in Mechanical and Electrical Engineering. (kidding)
2. Remove the seat and fuel tank. Unplug and remove the kill button and its
wiring.
3. EXC – Unplug and remove the headlight. MXC – Remove the front
number plate.
4. EXC - Unplug the stock taillight from the bike’s wiring harness (plastic
connector at the front of the airbox) and remove the rear fender/side panel
plastic from the bike. Unbolt and
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failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install the copper crush washer from the stock bolt under the switch (Photo 2). Torque to 25 lbs. Bleeding the Brake: (do not begin this process unless you have a fresh can of brake fluid.) Remove the lid from the rear brake reservoir (left side under carburetor.) Put the box end of a 11mm wrench over the caliper ble
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9. Rear Turn Signal Drill 13/32” hole here Installation: Looking at the Photo 5 (rear turn signal inside edge of the taillight, mounting location) locate the slightly raised “guides” on each side (see Photo 5). These are where the rear turn signals will mount on the taillight. Mark the center of these guides with an awl and drill a 13/32” hole through the center of each one. Mount two of the turn signals to these locations. 10. Rear Turn Signal and Route wires through hole
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• Attach one of the two wires (doesn’t matter which) from the Photo 8 left turn signal to the white wire from the gray cable. • Attach the two remaining wires from the turn signals to the black double-female connector from the gray cable. Once the connections are made, drill MXC Taillight Mounting several small holes and zip-tie the Hardware Locations harness into place along the same slot as the stock taillight wires as shown in Photo 7. EXC - You may now reinstall the tailli
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13. Front Turn-Signal Installation: Mount the front turn-signal mounting bracket to the upper triple- clamp as shown in Photo 12. Mount the front turn- signals to this bracket. Photo 12 EXC’s use the existing bolts to mount this bracket. MXC’s use the two Photo 13 Horn 6x12mm bolts found in the parts Flasher bag to mount this bracket. 14. Lens, Flasher, Horn, and Relay Relay Installation (’04 EXC Only): Replace the stock plastic 35W headlight lens with the provided 55/60W g
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17. Kill Wire Extension Installation: Locate the black/white and green two- wire extension in the dual-sport kit parts bag. It has a ring terminal and female connector on one end and two females on the other. Secure the ring-terminal to the ground bolt under the fuel tank (same bolt the stock kill button was removed from in step 3.) Attach the female connector to the black/yellow wire from the CDI module (wire the kill button unplugged from in step 3.) Route the extension to the front o
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19. Mid-Harness Connections: You will now make all the necessary wiring connections under the fuel tank and seat. • Under the fuel tank, locate the unused white 2-wire Photo 14 connector from the stock wiring harness (see Photo 14.) It may be bundled up in the stock wiring. Free this connector and attach it to the corresponding 2-wire connector from the Baja Locate this plug and attach it to Designs mid-harness (short its corresponding mate from the extension from the 6-pin
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The switch panel in this kit controls all the lighting functions in one compact package. Using the lighting selector, push the switch to the second position. The rear taillight should come on. Test the brake-light. Test the turn signals. Honk the horn (unless its after 11 PM!). Because the headlight is Kill Button powered directly off the coil, (not backed up by the battery) it will not Fourth Position:High turn on until the engine Beam is running. The low- beam will be li
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off the road. Make sure all the silicone rubber connector boots and the connectors are pushed firmly together and no bare metal is exposed. TROUBLESHOOTING Nothing happens when you turn the power switch on: • Fuse is blown. Check for bare wire or terminal shorting against the frame or another wire. • 6-pin connector not properly connected. • 2-wire connector under fuel tank is not properly attached to its mate from the Baja Designs wirin
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Baja Designs 185 Bosstick Blvd. San Marcos, California 92069 760.560.2252 www.bajadesigns.com
